DE102018213252A1 - Method for producing a plastic component and system for producing a plastic component - Google Patents

Abstract

For the economical production of an IMD plastic component (5), according to the method, an endless IMD process film (1), which has a carrier film (3) and a transferable IMD lacquer package applied to it on one side, becomes a close-fitting one with the IMD lacquer package individual cut to size to be decorated surface (6) of the IMD plastic component (5), this film cut (14) introduced into an open plastic processing tool (12), the plastic processing tool (12) completely or closed except for a residual stroke in the plastic processing tool (12) a flowable plastic mass is applied to the IMD lacquer package, a supporting structure is formed by the plastic mass, and the IMD lacquer package is transferred to the supporting structure as a decorative layer to form the IMD plastic component (5).

Description

The invention relates to a method for producing a plastic component, in particular IMD plastic component. Furthermore, the invention also relates to a system for producing such a plastic component, in particular an IMD plastic component, the system being set up in particular to carry out the aforementioned method.

An IMD plastic component is understood here and in the following to mean a plastic component which has an IMD lacquer package on an outside, which at the same time forms a visible surface of this plastic component. "IMD" stands for "in-mold decoration". This is a decorative process for plastic components, in which a lacquer package applied to an (endless) carrier film (also referred to as an “IMD lacquer package”) is transferred to the plastic component under the influence of pressure and temperature. The lacquer package is, for example, a lacquer layer (in particular a color lacquer layer, optionally also a clear lacquer layer), but preferably several layers of different functionality, in particular an adhesion promoter layer, one or more color lacquer layers and optionally a protective layer (in particular a clear one Protective lacquer) and / or a “release layer” (for easier detachment of the lacquer package from the carrier film). The semi-finished product formed from the carrier film and the IMD lacquer package is referred to here and in the following as an IMD process film or "IMD film" for short. Specifically, in an IMD process, the carrier film of the IMD film carrying the IMD lacquer package is usually backfilled with the melt of a thermoplastic plastic on the side carrying the IMD lacquer package. Due to the temperature and the pressure transferred by means of the plastic melt, the IMD lacquer package is detached from the carrier film and remains on the component formed by the solidified plastic melt. The IMD film - specifically the carrier film - itself does not form part of the IMD plastic component manufactured in this way.

“Backfeeding” is understood here and below in particular to mean that a flat decorative layer - such as, for example, B. the IMD paint package of the IMD process film described above - in particular molten thermoplastic is applied. The decorative layer is first introduced into a cavity (i.e. a mold cavity) of a plastic processing tool (for example a molding tool, often also commonly referred to as an injection molding tool) that defines the outer contour of the later plastic component. Then the plastic processing tool and thus the cavity is closed and liquid plastic - depending on the process variant - is applied and distributed to the decorative layer, for example by injection molding, injection molding, back pressing or also by thermoplastic foam injection molding. After solidification, the plastic forms a support structure for the decorative layer, in the case of the IMD process, for the IMD paint package remaining on the component. Deep drawing of the IMD film is also often carried out before the backing, in order to apply it to at least one wall of the cavity and to pre-form the outer contour of the later component. Since the backfeed takes place in the same tool in which the actual component is formed, this process is also known as the in-mold process. In terms of process technology, the IMD film is introduced from a roll into the plastic processing tool and the carrier film is rolled up onto another roll after the plastic component has been removed from the mold.

Most IMD plastic components are used as decorative components, for example in motor vehicles and often form dashboards, trim strips and the like provided with a metal look or a so-called "piano lacquer" or similar. The advantages of IMD plastic components lie in the very short cycle times, especially in thermoplastic processing, the low component costs for large quantities, and the very thin layer thickness of the often expensive decorative colors. Expensive and costly painting steps can advantageously be omitted with IMD plastic components. In comparison to a so-called insert technique, in which a decorative film remains firmly on the plastic component, the plastic component itself can be preceded by processing steps such as, in particular, reshaping the decorative film to the later component surface shape and thus additional tooling.

The object of the invention is to further improve an IMD method.

This object is achieved according to the invention by a method having the features of claim 1. The object is also achieved according to the invention by a system for producing an IMD plastic component having the features of claim 13. Advantageous and partly inventive embodiments and developments of the invention are shown in the subclaims and the description below.

The method according to the invention is used to manufacture an IMD plastic component. According to the method, an endless IMD process film (IMD film for short), which has a carrier film and a transferable IMD lacquer package applied to it on one side, becomes a close contour with respect to a surface of the IMD plastic component to be decorated with the IMD lacquer package cut foil cut individually. The film cut is then introduced into an open plastic processing tool (preferably an injection molding tool, hereinafter referred to as “molding tool”). The molding tool is then closed completely or at least apart from a residual stroke. A flowable plastic mass is then applied to the IMD lacquer package of the IMD film in the mold (which is at least closed to the remaining stroke). A support structure for the IMD plastic component is formed by the plastic mass. The IMD lacquer package is transferred to the supporting structure to form the IMD plastic component as a decorative layer.

The molding tool is then preferably opened, and the IMD plastic component is removed from the molding tool, specifically from a cavity (i.e. a mold cavity for forming the IMD plastic component) of the molding tool (“demolded”). The carrier film of the IMD film is detached from the IMD lacquer package during or after the demolding of the IMD plastic component.

As already described at the beginning, the IMD plastic component is therefore a plastic component to which a decorative lacquer package is transferred using the IMD film described above, in particular during the production of the plastic component itself. The carrier film of the IMD film does not remain on the IMD plastic component and therefore does not form part of the same.

The term “endless” is understood here and in the following in particular to mean that the corresponding “endless” element is many times larger than the intended component dimensions of the component manufactured by means of this element, for example at least 3-10 times larger, in particular has a longitudinal extension of such a length. In the case of the IMD film described above, it is preferably designed as a roll, in which the longitudinal extent can be more than 10 times, in particular more than 50 or 100 times the dimensions of the individual IMD plastic component.

The term “close to the contour” is understood here and in the following in particular to mean that the respective film cut conforms to the contour with respect to the surface to be decorated (in particular a visible surface of the later IMD plastic component) plus a process-related material surcharge (also called “edge-side protrusion” or “offset”) ) is formed. The material surcharge here serves in particular to ensure sufficient stretching of the elastic, in particular flowable, IMD film, which is preferably within process-related limits, in a “deep-drawing step” which is frequently carried out in the production of IMD plastic components, ie. H. to enable (in particular three-dimensional) reshaping of the IMD film. In particular, this material surcharge is dimensioned in such a way that the respective film cut can sufficiently lie against the, in this case, three-dimensional visible surface during such a reshaping step, in that material can be drawn in from the overhang on the edge by stretching or stretching without causing errors , for example decor warping, tearing of the decor, drapery, gaps in the decor or the like. The dimensions of the overhang on the edge are determined and specified in particular as a function of a “depth” of the three-dimensional structure of the visible surface to be decorated. In particular, the protrusion is also given greater as the depth of the structure increases, even if a base area of the structure projected onto the level of the IMD film remains the same.

The term “residual stroke” is understood here and below in particular to mean that the mold is not closed completely, but only to such an extent that leakage of the flowable plastic compound from the cavity, in particular by means of two mold halves of the mold, is prevented. For this purpose, the molding tool has a so-called plunge edge or the like in an optional variant. Such a residual stroke is expedient, for example, for a pressing or embossing step during or after the application of the plastic compound.

The cavity of the molding tool is preferably formed in each case by a partial cavity formed on a mold half (which is in particular delimited in each case by a mold surface). In principle, one of the two tool surfaces can also be designed as a projecting (convex) structure on a tool half, which at least partially projects into a recess (which represents the other partial cavity) delimited by the other tool surface in the closed state of the mold.

A “flowable plastic mass” is understood here and in the following to mean in particular a liquid molding compound which, through solidification, forms the supporting structure formed by plastic. In an expedient process variant, the flowable plastic mass is a thermoplastic melt. In an alternative process variant, a liquid mixture of reactive components of a crosslinking, in particular thermosetting plastic, becomes optional also used a reactive plastic foam.

Due to the fact that, according to the invention, single-cut foil blanks are used for the IMD process, the utilization of the available total area of the IMD foil, advantageously the entire roll width, in particular also a production width (e.g. about 600 millimeters) of a so-called mother roll, which is common depending on the individual decor, its width can be tailored to a delivery width. In particular, film areas that otherwise remain unused due to a film advance can also be used advantageously. Thus, the economy and sustainability (especially due to reduced, unused film waste) can be increased in the manufacture of the IMD plastic component. Furthermore, the plant outlay for feeding the roll-shaped IMD film into the mold can also be reduced.

Due to the use of the near-contour film blanks, the IMD method according to the invention described here and below is also referred to as “contour IMD”.

In a particularly expedient process variant, a multiplicity of film blanks are nested on the endless IMD film, in particular also transversely to the longitudinal direction of the roller conveyor (at least in sections) and then separated. The term “nest” is understood here and below in particular to mean that the plurality of film cuts with regard to their outer contour (thus taking into account the offset) while making maximum use of the area available on the IMD film (in particular the roller conveyor forming it) - d. H. while reducing the amount of waste that arises between the individual film cuts - in particular with different orientations of the individual film cuts (also: “nested”). Depending on the type of decor formed by the IMD lacquer package, an optional sub-variant can also be used to nest different cut geometries on the IMD film, which are used, for example, to decorate different IMD plastic components with regard to their geometry. This enables, for example, an even more efficient use of the entire area of the IMD film. In this variant of the method, an IMD film with a decor that is uniform over its entire surface, for example a uniform coloring and / or a uniform pattern, is preferably used.

In an optional process variant - also referred to as “single image contour IMD” - the assigned pattern (i.e. the decor) is formed for each foil cut nested as described above by means of separate application of the IMD lacquer package on the carrier foil (and thus locally different). For example, individual “color fields” that correspond to the outer contour of the respective film cut or at least to the surface of the plastic component to be decorated, after the (“virtual” or planned) distribution of the film cuts on the IMD film with the possibly several layers of the respective IMD film. Lacquer packs printed and the foil cuts separated afterwards. The overhang on the edge is optionally not printed, i. H. released. Furthermore, different individual image decors are optionally also applied to the carrier film, in particular using digital printing.

In any case (i.e. both with full-surface printed and with IMD film printed with individual images), the material expenditure at least of the carrier film of the IMD film can thus be reduced and thus the economy in the production of the IMD plastic component can be increased. With single-image contour IMD, paint can also be saved because only relevant areas of the IMD film are printed.

In an expedient process variant, the respective film blank is picked up by means of a handling tool before it is introduced into the plastic processing tool. In addition, a plurality of film blanks are preferably first arranged in a magazine (or a cassette), from which the film blanks are then individually taken up directly before the manufacture of the respective IMD plastic component by means of the handling tool, specifically. The use of the handling tool enables automation that is particularly advantageous for the series production of the IMD plastic component.

In an expedient development of the method variant described above, the handling tool preferably forms a clamping frame that is separate from the molding tool. By means of this clamping frame, the film blank is aligned with the cavity of the molding tool when it is introduced into the molding tool, that is to say it is positioned and preferably also centered with respect to the decor of the IMD lacquer package and the outer contour of the visible surface to be decorated. The alignment is preferably carried out specifically in relation to a partial cavity (which forms the surface of the mold cavity which forms the visible surface) which is formed on a mold half on the decor side (hereinafter referred to as “mold decor side”) of the mold. Optionally, the alignment can also be opposite a "back" half of the tool (opposite the tool decoration side). Preferably, the respective film cut is “held” in its intended orientation in the shaping tool by means of this clamping frame, preferably clamped against one of the tool halves, in particular against the tool decoration side. Simultaneous use of the handling tool as a clamping frame for the plastic processing process, which is preferably designed as an injection molding process (ie before the plastic material is introduced into the mold to form the supporting structure and, if appropriate, the subsequent cooling), advantageously simplifies the system technology. Optionally, several handling tools of this type are used together with (in particular “only”) one molding tool, for example by already taking the next film blank by means of a second handling tool, while the first film cutting is held in the molding tool by means of the other, first handling tool or after opening the molding tool Will get removed.

In an alternative method variant, the film blank picked up by means of the handling tool is transferred from this handling tool to a tool-side - ie. H. in particular as part of the molding tool and preferably arranged between the two tool halves of this molding tool, in particular in a moveable manner, with the clamping frame. By means of this clamping frame on the tool side, the film blank is then held (preferably clamped) relative to the cavity of the molding tool, in particular during the formation of the supporting structure. Alignment of the film cut is optionally carried out when it is transferred to the stenter. In this variant of the method, the handling tool in particular represents a gripper. The clamping frame on the tool side in this variant of the method is expediently designed as a kind of “lead”. H. in particular by means of spring elements (hydraulic, mechanical or pneumatic springs) movably arranged on one of the tool halves, in particular the rear (preferably the “fixed”) tool half. As a result, when the mold is closed, the film blank, in particular with the carrier film, comes into contact with the other half of the tool, in particular the tool decoration side, and the clamping force is built up. In this case, reshaping is expediently carried out during a pause in the closing movement, at which the clamping force is sufficiently high for reshaping. Then the mold is completely closed and then the plastic mass is introduced. In this variant of the method, the film cut is picked up by the gripper on the carrier film and transferred with the lacquer side to the stenter. The transfer is optionally carried out by a compressed air blast from the gripper.

In a preferred method variant, the or the respective film cut is held in a contour-following manner by means of the handling tool and / or the clamping frame on the tool side. The handling tool or the clamping frame on the tool side are therefore in particular shaped in such a way that the film blank is held along its outer contour, preferably within the overhang on the edge (i.e. the offset). The handling tool or the clamping frame is preferably designed so narrow that the film cut is expediently held only in the area of the offset and also as close as possible to the outer edge. For holding (gripping) the respective film cut, the handling tool and / or the clamping frame have, for example, suction cups, which are optionally coupled with a vacuum line, or a contoured retaining channel, which likewise has a vacuum line for “suctioning” and thus for holding supported by vacuum of the respective film cut. Furthermore, the handling tool and / or the respective stenter are optionally set up for electrostatically picking up or holding the film blank.

In order to keep moving masses in particular when picking up and inserting the respective film cut into the molding tool, the handling tool is designed in a preferred embodiment as a fiber composite element, for example as a thermosetting or thermoplastic, in particular continuous fiber reinforced, fiber composite component. This fiber composite component preferably also has a lightweight structure, for example a so-called skeletonization. Additionally or alternatively, the clamping frame on the tool side is also designed as such a fiber composite component.

In order, in particular for an optional reshaping of the respective film cut before the application of the plastic compound, in particular by means of deep drawing supported by a pressure difference (preferably by negative pressure), to enable a sufficient seal between the film cut and the corresponding tool half (in particular the tool decoration side) of the molding tool, In an expedient process variant, the film cut is pressed onto a sealing surface (referred to as “sealing contour”) of the molding tool by means of the separate or the tool-side clamping frame with its side facing away from the IMD lacquer package (thus with the carrier film). In particular, the separate or the tool-side clamping frame has a closing contour for this purpose, which is ring-like on the outer or edge contour the foil cut is arranged on the tenter frame. A sealing cord, also referred to as a “pressure ring”, a sealing rib or a comparable, optionally flexible element is preferably used as such a closing contour. By means of this (in particular ring-like closed, optionally also open) closing contour, when the clamping frame is applied to the corresponding tool half, the film blank is pressed linearly in a peripheral edge area and at least when using the resiliently designed closing contour under approximately uniform pressure against the sealing surface of the molding tool. In an optional variant, the closing contour of the clamping frame is stiff, in particular made of the same material as the entire clamping frame, and the sealing surface of the molding tool is formed by a flexible structure, for example the sealing cord mentioned above. In the event that the closing contour does not form a closed ring, sealing takes place in particular via the sealing contour of the molding tool, which is designed, for example, as an edge or a comparable sealing element. Optionally, the seal is supported by a vacuum created between the film cut and the corresponding partial cavity.

For (at least partial) reshaping of the film blank, a pressure difference is applied between the IMD film (specifically the carrier film) and the molding tool, in particular after the IMD film has been pressed onto the molding tool. In this case, a vacuum is preferably applied between in particular the tool decoration side and the film blank, under the effect of which the IMD film is at least largely applied to the surface of the part cavity on the decoration side. Optionally, the IMD film is only partially, i. H. in particular not applied to the surface of the corresponding partial cavity over the entire surface. In this case, residual, “complete” molding of the IMD film to the decor-side partial cavity takes place under the effect of the pressure of the introduced plastic compound, optionally also the temperature, especially in the case of thermoplastic melt. The pressure difference, in particular the negative pressure, is applied before, during or after the mold is closed. As an alternative or in addition to the negative pressure, an excess pressure is optionally applied, for example by means of a pressure bell. In this case, the tool decoration side has ventilation holes. A heating device is also optionally integrated in this pressure bell.

To support the forming process, the film blank is preheated in a suitable process variant. In this case, it is a question of thermoforming the film blank. For example. the film blank is preheated here by means of infrared radiators or a heating fan before it is introduced into the mold or even in the mold.

The separate or tool-side clamping frame is preferably guided in the mold on guide rods and held in the mold. These guide rods also position the film blank in relation to the cavity. Alternatively, the respective clamping frame is held in the tool by magnetic, electromagnetic or hydraulic holders. In the first case, the clamping frame has magnetic subregions, for example, and is introduced into the mold by means of a handling device, for example by means of an industrial robot, aligned and held by means of permanent magnets arranged in the mold. Alternatively, electromagnets integrated in the mold are activated so that the clamping frame is held in the mold, on the tool decoration side or on the back of the tool half. In the case of the hydraulic brackets, for example, clamping claws or the like are used, which are actuated hydraulically after the alignment of the respective clamping frame and clamp the respective clamping frame against the tool decoration side.

In a further optional method variant, the film blank is transferred from the handling tool - and thus after it has been picked up - to a holding structure which is arranged on a tool half, is fixed or is optionally movable in the closing direction. This holding structure is, for example, a plurality of individual suction cups, a holding channel (for the circumferential holding of the film blank by means of a negative pressure) or the like. In this case, therefore, no clamping frame is used, by means of which the respective film cut is held in the latter during and after the mold is closed. In particular, this holding structure, preferably the movable holding structure, is arranged on the rear tool half of the molding tool. In the event that the holding structure is an immovable, for example the holding groove introduced into one of the tool halves, this is optionally also arranged on the tool decoration side.

In a further expedient method variant, the respective film cut is aligned on the IMD film, in particular during the nesting, depending on the decor of the IMD lacquer package. For example, with a “pinstripe decor” (ie a decor with stripes running in one direction - optionally comparatively narrow - stripes), the respective film cut can only be made in two 180 degrees from each other on the IMD film. In the case of a uniform, single-color decor, the respective film cut can be rotated freely with respect to the IMD film. If necessary, however, it is also not possible to rotate the film blank, or even to rotate it by 90 degrees.

In a further expedient method variant, a molding tool with several cavities is used. A plurality of film blanks for shaping a plurality of IMD plastic components are introduced into this in parallel (i.e. in particular at the same time) in each of one of the cavities of the molding tool. Optionally, a separately assigned handling tool (possibly also a separately assigned stenter) is used for each film cut. As a result, the throughput or “output” can advantageously be increased with only one molding tool. In this case, the advantage is not only that the utilization of the entire IMD film is improved. Due to the use of individual film cuts, in the case of several cavities, “communication” between the respective film areas assigned to a plastic component is also avoided. In particular, the stretching during forming can therefore take place independently for each component without the individual strains influencing one another in the case of a coherent film over several cavities, and thus decor is distorted or the like.

The system according to the invention for producing the IMD plastic component described above is specifically set up to carry out the method described above. The system thus has the features and advantages described in the context of the method described above. The system specifically includes a plastic processing machine and the molding tool described above, which has the cavity for forming the IMD plastic component and is preferably arranged on the plastic processing machine. The plastic processing machine - in particular an injection molding machine for thermoplastics, thermosets or foams, a plastic press or the like - also serves to handle the mold, i. H. specifically for opening and closing, as well as for introducing the plastic compound into the (or the respective) cavity and onto the IMD film. Furthermore, the system preferably also includes a handling device carrying the handling tool, preferably an industrial robot, a portal gripper, a guide link or the like.

In an optional embodiment, the system also has the magazine described above for receiving the individual foil blanks. Optionally, the system also has a separating device, for example a so-called cutter, in particular a CNC cutter (which in turn has, for example, an ultrasound blade, a laser, a scraper, a water jet cutting nozzle or the like) for separating the respective film cut from the IMD Assigned slide.

As described above, the handling tool and / or the clamping frame is advantageously designed to follow the contour of the film blank and thus also the cavity of the molding tool. Optionally, the tenter frame can be folded - in particular in order to enable preforming or a comparatively high degree of deformation. H. in particular articulated transversely to a plane of the film blank.

The conjunction “and / or” is to be understood here and in the following in particular in such a way that the features or terms linked by means of this conjunction can be formed or occur both together and as alternatives to one another.

• 1 in einer schematischen Draufsicht ein Teilstück einer IMD-Prozessfolie,
• 2 in Ansicht gemäß 1 die IMD-Prozessfolie mit darauf angeordneten und verteilten Außenkonturen unterschiedlicher Folienzuschnitte,
• 3 einen aus der IMD-Prozessfolie vereinzelten Folienzuschnitt,
• 4 in einer schematischen Seitenansicht ein weiteres Ausführungsbeispiel des Folienzuschnitts sowie ein Handhabungswerkzeug, das zum Aufnehmen des Folienzuschnitts dient,
• 5 in Ansicht gemäß 4 das Handhabungswerkzeug, das den Folienzuschnitt aufgenommen hat,
• 6 in einer perspektivischen Ansicht das Handhabungswerkzeug mit dem aufgenommenen Folienzuschnitt,
• 7-10 jeweils in schematischer Seitenansicht ein Kunststoffverarbeitungswerkzeug, bei dem das Handhabungswerkzeug als Spannrahmen für den jeweiligen Folienzuschnitt verwendet wird, in unterschiedlichen Prozessphasen zur Fertigung eines IMD-Kunststoffbauteils,
• 11,12 jeweils in Ansicht gemäß 7 ein alternatives Ausführungsbeispiel des Kunststoffverarbeitungswerkzeugs in unterschiedlichen Prozessphasen, und
• 13 in Ansicht gemäß 3 ein weiteres Ausführungsbeispiel zweier Folienzuschnitte, die für unterschiedlich stark dreidimensional geformte IMD-Kunststoffbauteile gleicher Grundfläche vorgesehen sind.

Exemplary embodiments of the invention are illustrated in more detail below with the aid of a drawing. In it show:

• 1 a schematic plan view of a portion of an IMD process film,
• 2 in view according to 1 the IMD process film with the outer contours of different film cuts arranged and distributed on it,
• 3 a cut from the IMD process film,
• 4 In a schematic side view, a further embodiment of the film blank and a handling tool that serves to hold the film blank,
• 5 in view according to 4 the handling tool that has taken up the film cut,
• 6 in a perspective view, the handling tool with the film cut,
• 7-10 each in a schematic side view of a plastic processing tool, in which the handling tool is used as a clamping frame for the respective film cut, in different process phases for the manufacture of an IMD plastic component,
• 11 . 12 each in view according to 7 an alternative embodiment of the plastic processing tool in different process phases, and
• 13 in view according to 3 a further exemplary embodiment of two film blanks which are provided for IMD plastic components of the same base area which have different three-dimensional shapes.

Corresponding parts are always provided with the same reference symbols in all figures.

In 1 an IMD process film (short: "IMD film 1") is shown. With the IMD film 1 it is endless roll goods. In 1 is specifically only a part (section) of an entire roller conveyor that extends along a longitudinal direction 2 extends, shown. The IMD film 1 has a carrier film 3 on that on a front 4 (also: "paint side") an IMD paint package (not shown) is applied. The IMD paint package is used in the manufacture of an IMD plastic component 5 (S. 9 . 10 ) to form a decorative layer on the IMD plastic component in the intended state of use 5 visible surface. This surface is also referred to below as “visible surface 6”. Specifically, the IMD lacquer package is made in a so-called IMD process by applying a flowable plastic compound, in the present exemplary embodiment specifically a thermoplastic melt on the front 4 the IMD film 1 , specifically transferred to the IMD lacquer package itself, to a support structure formed by the plastic melt after it has cooled and solidified. The carrier film 3 is thereby released from the IMD lacquer package and thus does not remain on the IMD plastic component formed by the carrier structure and the IMD lacquer package transferred to it 5 ,

In order to make the IMD process more economical, a method for producing the IMD plastic component described in more detail below is used 5 carried out. To do this, first an outer contour 8th of a film area that is used to decorate the visible surface 6 is required. This outer contour 8th is in relation to the visible surface to be decorated with the IMD lacquer package 6 of the IMD plastic component 5 designed close to the contour. This outer contour corresponds in concrete terms 8th thereby an edge contour 9 (S. 3 . 13 ) the visible area 6 plus a (material) surcharge 10 which is a stretch of the IMD film 1 in the case of three-dimensional shaping of at least part of a cavity 11 a plastic processing tool, briefly as a "molding tool 12 “Designated (s. 7 ), is required. The surcharge 10 thus forms an edge overhang or “offset”. A variety of outer contours 8th is used as part of a virtual (specifically a CAD) model, taking advantage of the entire one on the IMD film 1 available space distributed and aligned differently. This step of arranging the multiple outer contours 8th on the IMD film 1 is also called "nesting".

As in 2 Different external contours are also shown in an optional embodiment 8th for different IMD plastic components 5 (ie components with a different face geometry) on the IMD film 1 arranged.

This on the IMD film 1 positioned outer contours 8th are cut into separate foil cuts in a subsequent process step by means of a cutting device, specifically a CNC cutter 14 (please refer 3 ) isolated. I.e. the foil cuts 14 are along the respective outer contour 8th from the IMD film 1 , specifically cut out of the roller conveyor forming this.

In an optional embodiment, the cut film blanks 14 subjected to a quality control - specifically by means of an optical scanner - and then according to their decor and / or their outer contour 8th stacked aligned to each other. The isolated foil cuts 14 are stored in a cassette (a "magazine").

In one in the 4-6 (Using an alternative embodiment of the film cut 14 ) The process step shown is the respective film cut 14 by means of a handling tool 16 added. This is the handling tool 16 to the outer contour 8th of the foil cut 14 adapted, therefore the outer contour like a ring 8th of the foil cut 14 designed as follows. For the sake of clarity, the outer contour is 8th shown only rectangular in the present embodiment. In addition, the handling tool 16 several suction cups 18 that, in the intended use, along an edge area (specifically within the surcharge 10 ) of the respective film cut 14 concern about this. The handling tool actually works 16 the foil cut 14 by means of the suction cups 18 on the front side carrying the IMD paint package 4 , The suction cups 18 are connected in a manner not shown with a vacuum line, so that a vacuum required for gripping and holding on the suction cups 18 can either be activated or deactivated.

Im in the 4-6 The illustrated embodiment forms the handling tool 16 at the same time a stenter 20 , by means of which the film cut 14 in a subsequent process step into the mold 12 is introduced (s. 7 ). While recording the film cut 14 becomes the handling tool 16 respectively. the stenter 20 “manipulated”, ie moved, using an industrial robot.

The film cut 14 is then facing the cavity 11 , specifically opposite one as a tool decoration page 22 designated tool half of the mold 12 aligned. On the tool decoration side 22 this is the half of the tool, part of the cavity 11 (hereinafter also: "partial cavity") for molding the visible surface 6 is trained. For alignment of the stenter 20 and thus also of the respective film cut 14 towards the cavity 11 becomes the stenter 20 on guide rods 24 - specifically by means of corresponding eyelets 26 - put on.

Then the stenter 20 against the tool decoration side 22 move and pressed. Thereby the foil cut 14 with its back, ie with the carrier film 3 against one around the one on the tool decoration side 22 trained part of the cavity 11 all-round sealing contour on the tool decoration side 22 is arranged (not shown in detail), pressed. In this exemplary embodiment, this sealing contour is an edge or rib that extends from the tool decoration side 22 protrudes slightly. To apply the film cut evenly 14 To enable this sealing contour is on the stenter 20 Contouring a closing contour in the form of a sealing cord, specifically a kind of elastic sealing ring. In 6 is a holding groove 28 shown for this sealing cord. In an alternative embodiment, the sealing contour is formed by the sealing cord and the clamping frame 20 has a corresponding rib as the closing contour.

The film is then cut using a radiant heater (specifically an infrared heater) 14 heated and then by means of a suction device, not shown, specifically a vacuum pump with associated suction lines, between the in the tool decoration side 22 trained partial cavity of the cavity 11 and the film cut 14 a pressure difference, specifically a negative pressure, so that the film cut 14 "creates" and is held on the surface of the partial cavity. The sealing contour and the closing contour hold the film cut 14 and make it possible to seal the space between the film blank 14 and the tool decoration side 22 ,

Then (or in an optional embodiment at the same time) one is used as the back of the tool 30 designated second tool half of the mold 12 towards the tool decoration side 22 process and thus the mold 12 closed. A the mold 12 load-bearing plastic processing machine, which is part of a system for producing the IMD plastic component 5 is and is specifically formed by an injection molding machine is in the 1 to 13 not shown in detail.

After closing the mold 12 a thermoplastic melt in the cavity 11 , specifically on the IMD paint package and thus on the front 4 of the foil cut 14 applied. The plastic melt creates a support structure for the IMD plastic component 5 trained to which the IMD paint package is transferred under the effect of pressure and temperature of the plastic melt. The IMD lacquer package forms a decorative layer on the supporting structure.

In a further process step, shown using 9 , the molding tool 12 opened and the IMD plastic component 5 , which is formed by the support structure formed by means of the plastic melt and the IMD lacquer package transferred thereon, from the carrier film 3 of the foil cut 14 solved. The carrier film 3 initially remains on the stenter 20 , In a subsequent process step, the stenter is also used 20 with the carrier film 3 from the mold 12 removed and the carrier film 3 then from the stenter 20 solved.

In an alternative embodiment, the in 7-10 shown stenter 20 a part of the mold 12 The handling tool 16 is used in this case to hold the respective film cut 14 , in this case specifically on the side of the carrier film 3 , and to hand it over to the tool-side stenter 20 (not shown in detail). The stenter 20 is in this case in a manner not shown with the mold 12 coupled (e.g. by the guide rods 24 longer than shown).

In 11 and 12 is another embodiment of the tool-side stenter 20 (shown in a schematic partial sectional view). In this case the stenter is 20 on the back of the tool 30 Movable as a so-called lead, specifically in the back of the tool 30 plunging feathers 32 attached. A ring-shaped closed frame (specifically a connecting bridge between the individual suction cups 18 ) is in 11 and 12 not shown in detail. The handling tool 16 takes the film cut in this embodiment 14 on the carrier film 3 and passes the foil blank 14 in the mold 12 to the stenter 20 , In the present embodiment, the film cut 14 from the handling tool 16 picked up by vacuum (ie sucked in). The film cut is used for transfer 14 to the suction cups 18 of the stenter 20 is applied and a short air blast is emitted so that the film cut 14 away from the handling tool 16 detaches and from the suction cups 18 is held. When closing the mold 12 comes the film cut first 14 with the tool decoration side 22 , specifically the sealing contour there in contact and the springs 32 are compressed so that a clamping force for the film cut 14 is built up. Then the film is cut 14 - if necessary with preheating - formed, specifically by means of a vacuum in the partial cavity of the tool decoration side 22 "Sucked in" and applied to the surface there. Then the molding tool 12 closed and the plastic melt into the cavity 11 and injected onto the IMD paint package.

In a further, alternative embodiment, the in 11 and 12 illustrated suction cups 18 not sprung and not connected by a frame, but provide a holding structure for the back of the tool 30 In this variant there is no stenter 20 for use. The handling tool 16 but passes the foil blank 14 in a manner corresponding to the exemplary embodiment according to FIG 11 and 12 ,

In 13 are two different film cuts 14 shown, each for the manufacture of an IMD plastic component 5 serve. The assigned IMD plastic components 5 in this case point the same to the level of the IMD film 1 projected area, therefore the same edge contour 9 but differ in the three-dimensional depth of their visible surfaces 6 , That is why the surcharge 10 at the in 11 film cut shown on the right 14 specified larger in comparison, to a greater material expansion when forming in the mold 12 to enable. Even the stenter 20 or the handling tool 16 are in this case for the film cut shown on the right 14 formed larger (not shown).

The object of the invention is not limited to the exemplary embodiments described above. Rather, other embodiments of the invention can be derived by the person skilled in the art from the above description. In particular, the individual features of the invention described with the aid of the various exemplary embodiments and their design variants can also be combined with one another in another way.

LIST OF REFERENCE NUMBERS

1

IMD foil

2

longitudinal direction

3

support film

4

front

5

IMD plastic component

6

viewing area

8th

outer contour

9

edge contour

10

surcharge

11

cavity

12

mold

14

film blank

16

handling tool

18

suction cup

20

tenter

22

Tool decorative side

24

guide rod

26

eyelet

28

retaining groove

30

Tool back

32

feather

Claims (13)

Method for producing an IMD plastic component (5), according to the method - From an endless IMD process film (1), which has a carrier film (3) and a transferable IMD lacquer package applied to it on one side, a close contour with respect to a surface (6) of the IMD plastic component to be decorated with the IMD lacquer package ( 5) the cut film blank (14) is separated, the foil blank (14) is introduced into an open plastic processing tool (12), the plastic processing tool (12) is closed completely or to a residual stroke, a flowable plastic compound is applied to the IMD lacquer package in the plastic processing tool (12), - A support structure is formed by the plastic mass, and - The IMD paint package for forming the IMD plastic component (5) is transferred as a decorative layer on the support structure. Procedure according to Claim 1 , with a large number of film blanks (14) on the endless IMD Process film (1) is nested and then separated. Procedure according to Claim 1 or 2 The foil blank (14) is received by means of a handling tool (16) before being introduced into the plastic processing tool (12). Procedure according to Claim 3 , wherein the handling tool (16) forms a clamping frame (20) separate from the plastic processing tool (12), by means of which the film blank (14) is aligned with a cavity (11) of the plastic processing tool (12) when introduced into the plastic processing tool (12) and in which Plastic processing tool (12) is held. Procedure according to Claim 3 , wherein the film blank (14) is transferred from the handling tool (16) to a tool-side clamping frame (20), by means of which the film blank (14) is aligned with the cavity (11) of the plastic processing tool (12) and held in the plastic processing tool (12) becomes. Procedure according to one of the Claims 3 to 5 , wherein the film blank (14) is held in a contour-following manner by means of the handling tool (16) and / or the tool-side clamping frame (20). Procedure according to one of the Claims 3 to 6 , wherein the handling tool (16) is designed as a fiber composite element. Procedure according to one of the Claims 4 to 7 , wherein the film blank (14) by means of the separate or the tool-side clamping frame (20) to a sealing surface of the plastic processing tool (12) for sealing against the cavity (11), in particular by means of an outer contour (8) of the clamping frame (20) Foil blank (14) following the closing contour is pressed. Procedure according to one of the Claims 1 to 8th , a pressure difference being applied between the side facing away from the IMD lacquer package and the plastic processing tool (12) for reshaping the film blank (14). Procedure according to Claim 3 The foil cutting (14) is transferred from the handling tool (16) to a holding structure arranged on a tool half (22, 30) of the plastic processing tool (12). Procedure according to one of the Claims 1 to 10 , wherein the respective film cut (14) is aligned as a function of a decor of the IMD lacquer package on the IMD process film (1). Procedure according to one of the Claims 1 to 11 , wherein the plastic processing tool (12) has a plurality of cavities (11), and wherein a plurality of film blanks (14) are introduced into one cavity (11) of the plastic processing tool (12), optionally by means of an associated handling tool (16). Plant for producing an IMD plastic component (5), set up to process the method according to one of the Claims 1 to 12 with a plastic processing machine, with the plastic processing tool (12) which has the cavity (11) for forming the IMD plastic component (5), and with a handling device carrying the handling tool (16), by means of which the film cut (14) into the Plastic processing tool (12) is introduced.

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